Wall-forming material and method of making the same



Jan. 5, 19,32. J, MAZER WALL FORMING MATERIAL AND METHOD O F MAKING THE SAME Filed Jan. 4,- 1928 2 Smets-Sheet INVENTOR Jan, 5, 1932. J, MAZER 1,839,404

WALL FORMING MATERIAL AND METHOD OF MAKING THE- SAME Filed Jan. 4, 1928 2 Sheets-Sheet 2 Patented Jan. 5, 1932;

UNITED STATES lPa'rlaN'r lOFFICE- J'COB MAZER, OF UPPER DAB-BY TOWNSHIP, COUNTY, PENNSYLVANIA 'WALL-FOBMING MATERIAL METHOD OF MAKING THE SAME Application mea January 4, 192s'. senti N o. 244,431..`

nature was desired. In applying any sheet of sound-absorbing material to a Wall or ceiling it is always necessary to make the sheet very much smaller than the area to be covered. In the course ofmany years in the practice of acoustical engineering, -my own 5 experience was'that aV sheet of hair felt (one of the most commonly used materials) could be handled and applied to best advantage if it were about two and one half square feet in area. (The maximum thickness of soundabsorbing material generally used is about 'one inch.) lt is clearly seen that even though the sheets used` were larger in area than that found most practical, there would of necessity be many seams at the edges of.

the sheets Where they abut one another. In order to obtain a finished surface 'whichis uniform in appearance, Without visible lines, seams or joints, it would be necessary to in some way eliminate the seams at the edges of the sheets Where they abut.. This is necessary because architects, decorators and the general public object in most instances to ce'ling and Wall surfaces which are divided tations of the absorbing materials heretofore used; oneof themost serious-limitations bei-ng that of size of sheet which can be applied as a unit.

Materialsl composed A of manufactured fibers, as hereinafter described, are of such .Nnature that they readily intermesh when pressed 'together by hand and ladjoining sheets maybe made to hate the appearance of a single 'sheet and a large Wallv or ceiling surface covered with many sheets .may be made to have a comparatively smooth`univ form appearance without visible lines, seams s or joints. This important quality-would Another important quality is that it may be painted with plastic or other formsof Water or oil paint without absorption of the paint into the fiber itself, since the materials used are not porous, in contrast tothe porous nature of hair, ,vegetable fiber and the like, which take up much paint, forming a hard-heavy surface, so much so that the ainted surface tendsto separate from the alance of thel mass. The painted surfaces of my :materialmay be of almost unlimited type and txture,lat 10W cost as the labor and quantity of material required is much less l than required for other forms of fibrous surface. i

Aside from the higher acoustical value due to the lighter, softer and more yielding surface, the material is one which, for the same reasons, is less liable to crack and which can be used 'anywhere that a light low cost, fire-resisting Wall or ceiling surface is desired, which can :be painted inwater--colors or with washable oil colors, which material may be used overtplasteror other surface or in place of it or even in place of a laster and lath wall vInthe latter case the brous layer receives the paint or plaster finish coat and has the decided advantage of flexibility which revents crackin and crazin The air and vegetale fibers re erred to have been open also to the objection that they decay, lose their elasticity, and tend to become infested Awith vermin. Furthermore, thefiber has been usually applied to walls, ceilings or the like, by workmen who are not skilled inacoustics, in accordance with some general directions as to the thickness of the material, with the result that only an approximate result in the Way of percentage of sound absorption has been secured. While. a given total absorption in a given room might be approximated, there would be lack of uniformity of absorption as between surfaces at different locations in the room.A

My invention has for one of its objects the emplo ment of materials,A preferably of manu actured fiber, suchv as mineral wool, steel wool, copper wool, spun glass, etc., in such manner and ofV such character as to secure the above-enumerated advantages and Ethe elimination of various objections. le feaaol , tures referred to as incident to the use of applied to walls,

' capacity is secured at all desired locations on walls, ceilings,

etc.,.and which will further permit' of a more uniform andneatly finished surface than in the case of some of the materials heretofore employed.

' glass,

Still another object of my invention is to provide a fibrous sound-absorbing medium that will embody in a common unit, the properties of comparatively great tensile strength, high capacity of sound absorption,

permanency as to physical composition, etc.,`. and which is of light weight.

While I hereinafter describe my invention more particularly in connection with manufactured fibers, such as metallic wools, spun etc., it will be understood that various of thel results which I describe may be secured by other fibers of various kinds.

The use of materials composed of hair, or other products of an animal or vegetable source, facture d, -limitsv the result obtained to the extent to whichthe qualities of the-raw materials are limited. Such limitations are very great and do not permit of predetermined values, except to a very vnarrow degree. It is obvious that inthe manufactured fiber,

even the very chemical'composition and the' physical characteristics of. each fiber can be predetermined.

Fibers of steel, copper, or other manufactured ber have a very important fundamental advantage in that the stren h, size, and p articularly the resiliency ande asticity, can e predetermined, and sheets or other units made of such fiber, in whole or in large part, can also `be accurately made-to have a definite and predeterminedyielding quality. This quality is given to the material so that it will yield to a much greater extent than other of the usual materials of construction, in response to the impact of a soundwave. It is usually desirable, in the regulation o f the acoustic propertiesof an auditorium'o'r other enclosure, to use a .material' which has very high sound-absorbing 4value'. However, itis very much more impLortant, and `in fact essential, to definite results tobe able to accurately create a material of a known coefficient `of absorption.

i Often, it is necessary to have a material'of Vlower sound-absorbing value than is available in a natural state, so that the total in contrast to those'that are manupanying drawings,

amount of material used, on the areas it is desirable to treat acoustically, does not exceed the total number of units of absorption required-to properly regulate the conditions for hearing in the room. Units made 'from the mineral fibers referred to can be so formed as to possess great tensile strength, since the fibers can be made in such forms when assembled, that they intermesh with one 'another and are of such nature, as compared to animal or vegetable fibers, that they cannot readily be torn apart, as can be determined by attempting to separate a mass of curled steel fibers, for example.

To still further bond together the fibers, I-

may galvanize them, as in the case'of steel fibers, in which case minute welds will form at the points of contact of the various fibers. This galvanized fiber may, in some cases, constitute substantially the entire sound-absorbing or facing unit or may be employed as a backing of relatively great tensile strength for a facing of fine mesh ungalvanized liber. It may also serve as metal lathto be placed over the framework of walls or ceilings.

' The fibrous body may have its exposed surface covered by a thin plaster coating or a coating of paint which may be applied with a brush or by spraying. Tests have shown that the surfacing material will not crack in use .nor even in handling, owing to the flexibility of the body. f

Some of he Ways in which my inventionV may be employed are vshown in the accom a portlon of a building structure to which sound-absorbing units embodying my invention havebeen applied; Fig. 2 is a viewshowing the material as applied to metal lath on a ceiling or wall structure; Fig. 3 shows another manner in which the material may be lied to a ceiling; Fig.l 4 shows a manner wherein Figure l showsa in which the material may be applied' to a column; Fig. 5 shows units that may be installed as in Figs. -l to 4; Fig. 6 is a view showing la sound-,absorbing unit in its simplest form; Fig. 7 shows a sound-absorb- .lng umt composed of an inner coarse layer and an outer fine layer of fiber; Fig. 8 is a view similar to that of Fig. 6, but showing the upper exposed surface of the units as covered by reinforcing material that may also serve as a finish cover; Fig. 9 is a view similar to Fig. 7, but showing a wire meshA o r metal lath reinforcement on the rear sur-` face of the unit, and by which .the unit may be attached to a supporting framework; Fig. 10 is a view showing the front and rear coverings of Figs'. 4 and 5,A combined in a single unit; Fig. 11 shows the unit of Fig. 6, with an internal reinforcement of wire mesh or the like; Fig. 12 shows the unit of Fig. 11, with facings of plaster or other smooth materia-l;

Fig. 13v shows one manner in which the soundabsorbing units may placed in alioor or A wall; Fig. 14 shows fibers assembled in loosekly woven form, and Fig. 15'is a view, on an enlarged scale, showing some of the various cross-sectional formsv which maybe given t0 individual fibers. j

While I herein refer more particularly to the matter of absorbing and dissipating sound waves in connection with the acoustics of an auditorium or the like, my invention is vnot so limited, because the invention will be utilized as sound and heat insulating materials inl the walls, floors and ceilings of buildings; as a wall facing material, as metal lath, and in various other Ways, Where sound control is not an essential or important factor. j

Referring to Fig. 1, I show walls having studding 16 to which is applied fibrous soundabsorbing material 17. j This material may be made in the form of units such as indicated in Figs. 5, 6 and 7 for example,n which can be glued to the studding, or secured thereto in any other suitable manner. The edges of adjacent units may be pressed together so that their projecting fibers interlock. In the case of metallic fibers, this interlocking effect is very pronounced, by reason of the hook-like and curly form given to the fibers, so that when pressed together the joint will ordinarily not `be discernible, and the units cannot be readily pulled apart. Ifdesired,the fibers at the edges of the panels or units can be brushed slightly to enhance the unitary effect produced by the panels when assembled in a wall. The-exposed surface of the fibrous body mayy be coated by acoating of paint or a coating of plaster, as heretofore eX,- plained.

In Fig. 2, I show ay floor sill 18 and joists 19 that may be of somewhat the'usual form. In this arrangement, sheets 20 of wire mesh or fabric such as expanded metal are securedy wto the j oists 19 by tie wires 21 that are passed through strands of the wire mesh and whose ends are twisted aroundthe joists. The iibrous material 22 can be attached to the mesh 20, either before application of the mesh to the joists or after the vmesh has been attached thereto, by pressing such material firmly against the mesh, so that the fibers will project through the openings in the mesh and become interlocked .with the strands thereof, as shown more clearlyfzjin Fig. 9. If desired, the tie wires 21 or other wires or sta les can be passed at least partially through theffibrous body, to serve also as means for holding it in ,j place against the mesh 20, or projecting bers may be twisted about strandsof the wire fabric.

In Fig. 3, `the fibrous material is represented by the numeral 23 and is shown as aliplied to a beamed ceiling structure c)4.

e fibrous material is secured to the ceiling 24 by lgluing or otherwise attaching it thereto and is 'shown as conforming to the/irreguin the way of character of material,

larities of ceiling surface that result from the presence of the beamed effect. The exibility and-tensile strength of the fibrous body is such that units` thereof may be simply placed against the ceiling and bent around the beam-like portions thereof, without danger of cracking or tearing'apart of the fibers containing the fibrous units. Here,as in F'ig. 1, the exposed surface of the fibrous body 23 ma be coated with paint or plaster as indicate in Fig.'12.

In Fig. 4, I show still another manner whereby fibrous units 17 may be made to conform to thecontour ofN non-plane surfaces. In this arrangement, certain of the units may terminate `at the lines a-a and b-b, and adjacent edges thereof pressed into enga e- .ment to form an unbroken connection getween the edges of the various units. As in the case of Fig. 3, the units could be merely bent to conform to the shape shown in Fig'.,4 and could also be bent to conform to columns or the like that are of circular or other contour.

In Fig. 6, vthe invention is shown in its,y simplest form, as comprising a sheet or la er made ofinterwoven or interlocked manu actured fibers of predetermined specifications as copper, steel, etc., length of fiber; thickness or diameter of fibers cross sectional form thereof, and galvanized or ungalvanized. Furthermore, the unit may be made of a thickness suitable for absorbing the desired percentage .0f sound. In the case of the shorter fibers, the body will be denser but have less tensile strength and elasticit than a body composed of longer bers an a body composed of thinner fibers can be compacted more than a bodypf thicker fibers,but mayhave less tensile strength. Also, fibers that are fiat or are noncircular in cross section will have agreater tendency to curl than-those which are circular, thus producing a. reater intermeshing or interlocking of the fiers.

fn Fig. 7, IX show a unit composed of a layer 17a of fine texture fiber and a layer 175 of coarser texture. "The fibers at the adjacent unit, the coarser` `fiber has greater tensile strength thathe finer fiber, and not only serves as a support for the fine ber, and perhaps also as a metal lath, but possesses the Capacity of sound absorption. The ne texture layer has relatively great sound-absorbing capacity, and also presents a smoother and more finished surface than lwould the coarser fiber, and lends itself more readily to decoration. y

The unit of Fig. 7, therefore, possesses greater strength and is cheaper than if`it were composed entirely of the fine mesh fiber, and possesses greater sound-absorbing capacity and is of neater appearance than if formed entirely of the coarser fiber.

Instead of providing a reinforcement mesh of woven wire or expanded metal upon the inner surface of the fiber, as shown in Figs. v2 and-9, mesh 20a may be placed upon the in Figs. 11 and 12. In the latter instance, a

facing of paint or plaster 25 is provided upon each surface of the fibrous body.. In this case, the body could serve as a partition with both sides of finished appearance and be sufficiently stiffened and strengthened by the mesh 22?).

In Fig. 13, 26 represents a base, such as a concrete slab. Strips 27 of fibrous material are placed upon the slab, while sleepers or sills 28 are placed upon the strips. Flooring 29 is nailed to the sleepers, and the space between the flooring and between the sleepers may be left open or filled with concrete, dry sand, etc., and pipes or conduits 30 may be conveniently placed between the flooring andthe slab. The fibrous strips 27 serve as cushions to absorb vibrations, as when machinery r,is located upon the fioor, and to decrease transmission of sound. In Fig. 14, I show a composite fibrous body relatively fibrous body of woven-like form, composed of strands 31 of metallic fibers twisted to rope-like form and interwoven. Such a body could be conveniently employed where much greater tensile strength is desired than in the case of the body of Fig. 6, for example, and Where it is desired that the fibers be more firmly interwoven so that the body is less subject to distortion.

If still further sound-modifying lor insulating properties are desired in the fibrous body than is conveniently obtainable by the use of metallic fibers of variousv sizes and materials, other fibers such as asbestos, mineral wool, etc., may be interspersed with the metallic fibers, to any desired extent, the

thus formed possessin g the various advantages in the waypof tensile strength, permanency, etc., of the metallic fibers, and also possessing various characteristics ofthe other fibers referred to, besides being perhaps less expensive than a body composed entirely of manufactured or metallic fibers.

.l/In addition to varying the thickness and length of fibers to suit certain conditions, I will also vary the .chemical composition of the metal entering into the manufacture of such fibers, to secure a desired de ree of strength, flexibility and elasticity. or example, in the ca se of steel fibers, I will increase the carbon content thereof, where great tensile. strength and resil- :mmm is wannirpd i'n the fibrous bodv.

smaller percentage of carbon will be employed where it is desired that the fibers and the body composed thereof shall be more.

other metals would be similarly provided for the purpose of securing these various characteristics.

' Furthermore, the fibers may severally be of various cross-sectional forms, as shown in Fig. 15. Thus a fiat fiber a would tend to curl more than the fibers b, c,y d, e, and f, but would also be susceptible ofbeing employed for forming a more compact mat. Employment of fibers b, e, or f, would result in a greater amount of air space in a mat formed thereof, while fibers c and cl possess greater tensile strength and less elasticity than some of the other fibers." These comparisons are merely illustrative, and do not exhaust the possibilities in the way of flexibility, tensile strength, porosity, etc., of a body containing any one, or various combinations of these or other forns of fibers.

While the term wall is employed in the appended claims, it will be understood that the term is used in its broad sense to include ceilings, floors, colunms, beams, and any other structure to which the material may be applied. The term plastic material is employed to designate broadly any liquid or semi-liquid substance such as paint or plaster, for coating the surfaces of the fibrous body. I

I claim as my invention 1. The method which comprises assembling metallic fibers,l into inter-meshing relation to form a self-sustaining mat-like body, placing a plurality of said bodies upon a support to form a wall structure, and causing the fibers at the edges of each body to intermesh with the fibers of adjacent bodies to form a composite Whole.r i

2. A sound-absorbing body for use on exposed wall surfaces, composed of looselymatted metallic fibers of a hardness not substantially greater than thatof mild steel.

3. A sound-absorbing body for use on eX- posed wall surfaces, composed of a plurality of layers of loosely-matted metallic. fibers, one layer being, of a hardness not substantially greater than that of mild steel.

4. A sound-absorbing body for use on exposed wall surfaces, composed of looselymatted metallic fibers of different thickness, paft of the fibers being of a hardnessnot substantially greater than that of mild steel.

5. A sound-.absorbing bodyfor use on e. posed wall surfaces, y composed ofY looselymatted fibers.a substantial number of which are of metal and have a hardness not substantially Vgreater than that of mild steel.

6. A sound-absorbing body for use on exposed Wall surfaces, composed f loosely- '5 matted metallic fibers, and containing a thin coating of plastic material on one lside thereof which partially imbeds' some of the fibers.

7. A sound-absorbing body for use on exposed Wall surfaces, composed of 1ooselymatted metallic fibers, and containing a thin vcoating of plastic material on one side thereof which partially imbeds some of the fibers, the fibers being of a hardness not substantially greater than that of mild steel. 8. A sound-absorbing body for use on eX- posed Wall surfaces, composed of looselyn matted fibers, a substantial number of which are of metal, and having a thin coating on one side thereof which partially imbeds some of the iibers.

9. A sound-absorbing body foi use on exposed Wall surfaces, composed of loosel matted metallic bers, and containing a thm flexible facing in adhering relation to'one side of the body.

ln testimony whereof l, the said JACOB MAzER, have hereunto set m hand.v

' JA OB MAZER. 

